Gap filler roller assembly

ABSTRACT

Roller assembly for forming adjacent curved surfaces in a composite gap filler member includes a first roller supported by a first support member, a second roller supported by a second support member and a support including a surface. First roller and the second roller are in contact with one another and in contact with the surface. With rotation of the first roller about a third axis and with at least one of the first roller or second roller moved relative to the other such that the first roller maintains contact with the second roller and the first roller and the second roller maintain contact with the surface, such that the first roller, second roller and the surface form an aperture having a first curved side having a first radius adjacent to a second curved side having a second radius wherein the first radius and second radius are unequal.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 16/018,538 (filed Jun. 26, 2018), the entirety of which isincorporated by reference herein.

FIELD

This disclosure relates to forming composite gap filler, and moreparticularly, to an assembly for forming a curved surface configurationalong adjacent sides of the composite gap filler.

BACKGROUND

Gap fillers are used in conjunction with a wide variety of structures.In an example gap fillers are used in association with a stringer usedin reinforcing portions of a skin structure of an aircraft. Thestringer, in one example, is constructed of pair of c-shaped channels.Each c-shaped channel has a web portion with a flange portion extendingfrom each end of each web portion. The flanges of each web portionextend away from the web portion with a corner formed between eachflange and its corresponding web portion with an outer surface of eachcorner forming a curved surface.

With the web portion of each of the two c-shaped channels positioned inabutting relationship with one another and secured together a stringeris formed. The flanges of a first end of a stringer are aligned with andextend in opposite directions from one another. On an opposing secondend of the stringer the flanges are aligned with and extend in oppositedirections from one another. As a result, on the first end of thestringer the outer surface of the corners extending between the flangesand their corresponding web portions form curved surfaces which arepositioned adjacent to one another and similarly the outer surfaces ofthe corners extending between the flanges and their corresponding webportions form curved surfaces on the opposing second end of the stringerare positioned adjacent to another.

With the first end of the stringer positioned against a skin, the twoadjacent curved surfaces associated with the first end of the stringerand the skin form a gap, wherein the gap extends along the length of thefirst end of the stringer. With the opposing second end of the stringerhaving a cap structure positioned in overlying relationship with theopposing second end of the stringer, the two adjacent curved surfacesassociated with the opposing second end of the stringer and the capstructure form a gap wherein the gap extends along the length of theopposing second end of the stringer.

A composite gap filler is needed to be positioned in each of these gapspositioned on the first end and the second opposite end of the stringerto enhance the strength of the stringer and to reduce the amount ofmaterial needed to construct the stringer in providing support to theskin structure. The gap formation in each instance has three sides aspreviously discussed. Two adjacent sides are curved and can change inradius of curvature as the gap progresses along the stringer as well asthe overall size of the gap. The changes in the gap configuration occursas load demands change along the stringer changing the size of thestringer and changing the radius of curvature of the of the outsidecurved surfaces of the corners formed between the flanges and theircorresponding web portion. As a result, gap fillers are fabricated toaccommodate these changes to the overall size of the gap and the changein radius of the adjacent curved sides of the gap.

In one example, the change in size of the stringer can occur in the wingof the aircraft. The load on the stringer is greater proximate to thefuselage than at the end of the wing wherein the size stringer and thesize of the gap filler may be the largest and the radius of curvaturefor the gap and the gap filler may be at their greatest dimension. Thestringer and the gap filler generally diminish in size as does theradius of curvature of the gap filler as load demands decrease as eachextend away from the fuselage location toward the outboard end of awing. However, as the stringer and gap filler approach the location ofan engine mounted on the wing, the load demand increases and thestringer and gap filler are increased in size as well as the radius ofcurvature of the gap and the gap filler increase in dimension. As thestringer and gap filler extend beyond the location of the engine towardthe outboard end of the wing, the load demand decreases on the wing andthe stringer and gap filler consequently decrease in size so as does theradius of curvature of the gap and the gap filler. In this example, asthe stringer increases in size so does the gap and the gap filler aswell as the dimension of the radius of curvature of the adjacent gapsides defined by the adjacent curved external surfaces extending betweenthe flange and its corresponding web portion and the dimension of theradius of curvature of adjacent sides of the gap filler. As the stringerdecreases in size so does the gap and the gap filler as well as thedimension of the radius of curvature of the adjacent gap sides definedby the adjacent curved external surfaces extending between the flangeand its corresponding web portion and the dimension of the radius ofcurvature of adjacent sides of the gap filler. As a result, there is aneed to increase and decrease the size of the gap filler as well as theradius of curvature of each of the two adjacent sides of the gap fillerso as to optimize the fit of the gap filler within the gap as the gapextends along the length of the stringer. Optimally fitting the gapfiller with the gap optimizes the stringer performance.

Particular difficulties have arisen in fabricating composite gapfillers. In one instance, where the gap filler material is pulledthrough guillotine dies which impart a curve to the gap filler onadjacent sides of the gap filler, it is problematic to fabricate the gapfiller from a smaller sized gap filler to a larger sized gap filler. Inincreasing the dimension of the gap filler, additional tape of laminatematerial is added to the existing gap filler, however the added tape oflaminate material is not secured to the existing gap filler materialbeing formed. With the addition of tape there is an increase in fiberswithin the gap filler. With the gap filler material experiencing atension force being pulled through the rollers forming the gap filler,the added material is not secured and placed in tension. As a result,the added fibers tend to be scraped off by the guillotine dies informing the adjacent sides of the gap filler being increased in size.

In other instances when a radius of curvature to the adjacent sides ofthe gap filler needs to be changed, guillotine dies or roller sizes arechanged that impart a different radius of curvature. However, the newlyinstalled roller immediately imparts a different radius of curvature tothe gap filler causing an abrupt change to the surface of the adjacentcurved sides of the gap filler. There is no transition provided in thesurface of the gap filler with the changing of the radius of curvature.This changing of rollers took time and resulted in a non-continuous orabrupt surface change on the gap filler. This lack of transition inradius change on the gap filler did not optimize the fit of the gapfiller with the gap it was intended to fill wherein the gap providedsmooth transitions of change of radius of the adjacent sides of the gap.As a result, the performance of the stringer was not optimized.

There has been use of rollers that were changed in position such as theplane of the axis of rotation of the rollers relative to the gap fillerbeing fabricated in order to change size and radius in the gap to befilled. Even though different sized rollers were not employed, a changewas made in the position of the plane of the axis of rotation of therollers relative to the gap filler to impart a different radius and sizewithout a rotation of the axis of rotation of the rollers about an axisof rotation positioned transverse to the axis of rotation for eachroller to provide for a transitional change in the radius of the gapfiller.

There is a need for providing a gap filler fabrication assembly thatwill reliably form gap fillers regardless of whether the gap filler isincreasing or decreasing in size along the length and the adjacentcurved sides of the gap filler are increasing or decreasing in theradius of curvature of the adjacent curved sides of the gap filler. Inaddition, there is a need not to have the change in configuration of thegap filler drive stringer design. There is also a need to change theradius of the curvature of each of the adjacent sides of the gap filleras the gap filler is fabricated such that the gap filler results inhaving a transition between changes in radius of curvature along thesurface of the gap filler without imparting non-continuous or abruptsurface changes on the gap filler surfaces provide different radii ofcurvature to adjacent sides of the gap filler. In addition, there is aneed to provide an assembly and a method to make a quality reliable gapfiller configuration so as not to impact aircraft assembly schedules.

SUMMARY

An example includes a roller assembly for forming adjacent curvedsurfaces in a composite gap filler member which includes a first rolleris supported by a first support member wherein the first roller rotatesrelative to the first support member and second roller is supported by asecond support member wherein the second roller rotates relative to thesecond support member. The first support member is rotatable about athird axis of rotation. The second support member is rotatable about afourth axis of rotation. The roller assembly further includes a supportwhich includes a surface wherein with the first roller and the secondroller in contact with one another and in contact with the surface andwith rotation of the first roller about the third axis of rotation andwith at least one of the first roller or second roller is moved relativeto other such that the first roller maintains contact with the secondroller and the first roller and the second roller maintain contact withthe surface, the first roller, second roller and the surface form anaperture. The aperture includes the first roller defining a first curvedside of the aperture having a first radius and the second roller definesa second curved side of the aperture, adjacent to the first curved side,having a second radius such that the first radius and the second radiusare unequal.

An example includes a method of forming adjacent curved surfaces in acomposite gap filler member which includes a step of positioning a firstroller, which is supported by a first support member in contact with asurface of a support, wherein the first roller rotates relative to thefirst support member and the first support member is rotatable about athird axis of rotation. The method further includes a step ofpositioning a second roller, which is supported by a second supportmember, in contact with the surface of the support and in contact withthe first roller, wherein and the second roller rotates relative to thesecond support member and the second support member is rotatable about afourth axis of rotation. The method further includes a step of pullingthe composite material in contact with and past the first and secondrollers wherein the first roller rotates and the second roller rotates.The method further includes a step of rotating the first support memberand the first roller about the third axis of rotation and moving atleast one of the first roller or second roller relative to othermaintaining the first and second rollers in contact with one another andin contact with the surface. The first roller, the second roller and thesurface of the support define an aperture. The first roller defines afirst curved side of the aperture having a first radius and the secondroller defines a second curved side of the aperture, adjacent to thefirst curved side, having a second radius such that the first radius andthe second radius are unequal.

The features, functions, and advantages that have been discussed can beachieved independently in various embodiments or may be combined in yetother embodiments further details of which can be seen with reference tothe following description and drawings.

BRIEF SUMMARY OF THE DRAWINGS

FIG. 1 is a plan view of an aircraft;

FIG. 2 is an exploded perspective view of a stringer with a first gapfiller positioned extending along a first end of the stringer and asecond gap filler positioned along an opposing second end of thestringer;

FIG. 3 is a perspective view of a roller assembly imparting a curvedsurface to adjacent sides of a gap filler along with a first embodimentof a support for the gap filler;

FIG. 4 is a perspective view of an example gap filler formed by theroller assembly in FIG. 3 wherein the dimension of the radius of each ofthe adjacent sides of the gap filler and size of the gap filler changeas the gap filler progresses along a length of the gap filler from afirst end to a second end of the gap filler;

FIG. 5 is a top plan view of the roller assembly of FIG. 3;

FIG. 6 is an enlarged partial front plan view of the roller assembly ofFIG. 3 with gap filler in cross section passing through the rollers;

FIG. 7 is a cross section view of the roller assembly taken along line7-7 in FIG. 3;

FIG. 8 is a perspective view of the roller assembly of FIG. 3 whereinthe axis of rotation of each of the rollers have been rotated inopposite directions about an axis of rotation of a support member ofeach of the rollers and each of the axis of rotation of each of therollers have also been moved along the axis of rotation of the supportfor each roller;

FIG. 9 is an enlarged partial front plan view of the roller assembly ofFIG. 8 with the gap filler in cross section passing through the rollerswith the rollers rotated and moved as shown in FIG. 8 to form adifferent radius and size for gap filler than shown in FIG. 6;

FIG. 10 is a perspective view of the roller assembly of FIG. 3, withouta gap filler passing through the rollers along with a second embodimentof the support for the gap filler;

FIG. 11 is a flow chart of a method of forming adjacent curved surfacesin a composite gap filler member; and

FIG. 12 is a perspective view of a second embodiment of the rollerassembly of FIG. 3 imparting a curved surface to adjacent sides of a gapfiller;

FIG. 13 is an enlarged partial front plan view of the second embodimentof roller assembly of FIG. 12 with gap filler in cross section passingthrough the rollers, wherein the rollers are positioned forming adjacentcurved surfaces of the gap filler to each have a same radius ofcurvature;

FIG. 14 is a partial front plan view of the second embodiment of rollerassembly of FIG. 12 with gap filler in cross section passing through therollers wherein the rollers are positioned forming adjacent curvedsurfaces of the gap filler to each have a different radius of curvature;

FIG. 15 is an enlarged partial front plan view of the second embodimentof the roller assembly of FIG. 14 with gap filler in cross sectionpassing through the rollers;

FIG. 16 is a perspective view of an example gap filler formed by thesecond embodiment of the roller assembly of FIG. 12 wherein the curvedadjacent surfaces of the gap filler differ in radius of curvature; and

FIG. 17 is a flow chart of a method of forming adjacent curved surfacesin a composite gap filler each having different radius of curvature.

While various embodiments have been described above, this disclosure isnot intended to be limited thereto. Variations can be made to thedisclosed embodiments that are still within the scope of the appendedclaims.

DESCRIPTION

Stringers are reinforcement members fabricated to be secured to skinstructures often used in aerospace construction. Stringers provideadditional strength to a skin structure thereby avoiding the need to addadditional laminates to the skin structure and adding correspondingadditional weight to the skin structure. This skin stringer andstructure is used in fabrication of aircraft such, as for example,aircraft 10, as seen in FIG. 1. Portions of aircraft 10 are constructedwith a reinforced skin structure utilizing stringers such as, forexample, fuselage 12, wings 14, horizontal stabilizers or tail wings 16and vertical stabilizer 18. Stringers can take on any number ofconfigurations and sizes depending on the load demands and spaceavailability with respect to the portion of aircraft being constructed.

An example of a configuration for stringer 20 can be seen in FIG. 2wherein stringer 20 is constructed of a pair of c-shaped channelsincluding first and second c-shaped channels 22, 24. First c-shapedchannel 22 has a first web portion 26 with a first flange 28 extendingfrom first web portion 26 on first end 30 of stringer 20 and secondflange 32 extending from first web portion 26 from second opposite end34 of stringer 20. Second c-shaped channel 24 has second web portion 36with first flange 38 extending from second web portion 36 on first end30 of stringer 20 and second flange 40 extending from second web portion36 on second opposite end 34 of stringer 20.

First flange 28 of first c-shaped channel 22 forms first corner 42 withfirst web portion 26 and second flange 32 of first c-shaped channel 22forms second corner 44 with first web portion 26. Similarly, firstflange 38 of second c-shaped channel 24 forms third corner 46 withsecond web portion 36 and second flange 40 of second c-shaped channel 24forms fourth corner 48 with second web portion 36. Each of first andsecond corners 42, 44 have first curved surface 50 and second curvedsurface 52 respectively. Similarly each of third and fourth corners 46,48 have third curved surface 54 and fourth curved surface 56respectively.

With the first and second web portions 26, 36 positioned in abuttingrelationship with one another and secured together, stringer 20 isformed. First flange 28 and first flange 38 on first end 30 of stringer20 are aligned with one another and extend in opposite directions fromone another. As a result, first corner 42 and third corner 46 arepositioned adjacent with one another with first curved surface 50 andthird curved surface 54 positioned adjacent to one another. On anopposing second opposite end 34 of stringer 20, second flange 32 andsecond flange 40 are aligned with one another and extend in oppositedirections from one another. As a result, second corner 44 and fourthcorner 48 are positioned adjacent to one another with second curvedsurface 52 and fourth curved surface 56 positioned adjacent to oneanother.

With first end of stringer 20 positioned against a skin structure (notshown) in FIG. 2, the skin structure and first and third curved surfaces50, 54 on the first end 30 of stringer 20 form a three sided gap (notshown) which extends along length L of stringer 20. First gap filler 58is provided to fill the three sided gap which extends along first end 30of stringer 20. With second opposite end 34 of stringer 20 having a capstructure (not shown) positioned in overlying relationship with thesecond opposite end 34 of stringer 20, the cap structure and secondcurved surface 52 and fourth curved surface 56 on second opposite end 34of stringer 20 also form a three sided gap (not shown) which extendsalong length L of stringer 20. Second gap filler 60 is provided to fillthe three sided gap which extends along length L of stringer 20 onsecond opposite end 34.

First and second gap fillers 58, 60 are needed to be positioned in eachgap formed on the first end of stringer 20 and the gap formed on thesecond opposite end 34. First and second gap fillers 58, 60 areconstructed of composite material as is in this example the first andsecond c-shaped channels 22 and 24. The gap fillers 58, 60 are needed toprovide an optimal fit within the gap on the first end 30 and the secondopposite end 34 and secure to all three sides of the gap providingstringer 20 the needed strength in providing support in this example tothe skin structure (not shown). The size of stringer 20 and the size ofthe gap along the first end 30 and second opposite end 34 of stringer 20can change in size depending on the load demands being placed onstringer 20. With the change in size of stringer 20, a resulting changeoccurs to the size of the gap and the radius of curvature of adjacentsides of the gap. As a result, the gap fillers 58, 60 to provide anoptimal fit within the gap of stringer 20, the size of gap fillers 58,60 need to corresponding change in size and the adjacent curved sides ofthe gap fillers 58 and 59 need to change as well.

Roller assembly 62, as shown in FIG. 3, provides for formation of gapfiller member 64, as seen for example in FIG. 4 and earlier described,for example, as first and second gap fillers 58 and 60 wherein changesto size and to dimension of radius of adjacent sides of gap fillermember 64 are needed for accommodating an appropriate fit with stringer20 along length L of stringer 20. The formation of gap filler member 64,as seen in FIG. 4 for example, will be accomplished with roller assembly62 providing smooth transitions along external surfaces 66, 68 ofadjacent curved sides 70, 72 respectively of gap filler 64 as gap fillermember 64 changes in size and adjacent curved sides 70, 72 change inradius of curvature along length L′ of gap filler 64. For example, firstsize S of gap filler member 64 and adjacent curved sides 70, 72 haveradius of curvature 76 at first end 74 of gap filler member 64. As gapfiller member 64 extends along length L′ gap filler 64 changes in sizeto an increased second size S′ and increased second radius of curvature78 of adjacent curved sides 70, 72. As will be discussed in furtherdetail herein, the change in size of gap filler member 64 and the changein radius of curvature of adjacent curved sides 70, 72 will have asmooth transition with respect to external surfaces 66, 68 withapplication of roller assembly 62.

In the example shown in FIG. 4, gap filler member 64 transitions fromsecond size S′ back to a smaller first size S at second end 75 andtransitions from second radius of curvature 78 of adjacent curved sides70, 72 back to a smaller first radius of curvature 76 for adjacentcurved sides 70, 72 at second end 75 of gap filler member 64. Thisexample demonstrates a relatively symmetrical configuration of gapfiller member 64 along length L′ of gap filler 64. As will beappreciated herein, roller assembly 62 can transition adjacent curvedsides 70, 72 to attain different sizes to gap filler 64 as desired alonglength L′ of gap filler 64 and attain changes in radius of curvature ofadjacent curved sides 70, 72 as desired along length L′ of gap filler64. The changing of size and radius of curvature of adjacent curvedsides 70, 72 will be imparted to gap filler member 64 by roller assembly62 with imparting a smooth transition of external surfaces 66, 68 alonglength L′ of gap filler member 64 without placing abrupt changes inexternal surfaces 66, 68.

In referring to FIGS. 3 and 5-6, roller assembly 62 is shown withrespect to imparting first size S and first radius of curvature 76 togap filler 64 as described above and shown in FIG. 4. Roller assembly 62can be constructed in a number of various constructions to accomplishimparting smooth transitions of size and radius of curvature to externalsurfaces 66, 68 of adjacent curved sides 70, 72 in forming gap fillermember 64. One example of roller assembly 62 is shown herein as anexample of a construction of an assembly that will accomplish the smoothtransition of external surfaces 66, 68 of adjacent curved sides 70, 72along gap filler 64 as size of gap filler member 64 changes and asradius of curvature of adjacent curved sides 70, 72 change along lengthL′ of gap filler 64.

Roller assembly 62, as shown in FIGS. 3 and 5-7, forms adjacent externalsurfaces 66, 68 in composite gap filler member 64. Roller assembly 62includes first roller 80 supported by first support member 82 whereinfirst roller 80 rotates relative to first support member 82 about firstaxis of rotation 84. Second roller 86 is supported by second supportmember 88 wherein second roller 86 rotates relative to second supportmember 88 about second axis of rotation 90. First support member 82, asseen in an example of roller assembly 62 in FIG. 7, is supported byfirst frame member 92 wherein first support member 82 rotates relativeto first frame member 92 about third axis of rotation 94 and third axisof rotation 94 extends in direction 96 transverse to first axis ofrotation 84. Second support member 88 is supported by second framemember 98 and is configured with second support member 88 as that offirst support member 82 and first frame member 92 as shown in FIG. 7.Second support member 88 rotates relative to second frame member 98about fourth axis of rotation 100, as seen in an example of rollerassembly 62 in FIG. 6, and fourth axis of rotation 100 extends indirection 102 transverse to second axis of rotation 90 in similarconfiguration as first support member 82 rotates relative to first framemember 92 about third axis of rotation 94 and extends in direction 96transverse to first axis of rotation 84, as shown in FIGS. 6 and 7.

As seen in FIG. 6, first axis of rotation 84 extends in first direction104 and second axis of rotation 90 extends in second direction 106wherein first and second directions 104, 106 extend in convergingrelationship toward one another. Third axis of rotation 94 extends indirection 96 and fourth axis of rotation 100 extends in direction 102such that directions 96, 102 converge toward one another. In thisembodiment, third axis of rotation 94 and fourth axis of rotation 100converge in a transverse relationship toward one another and in thisexample at ninety degrees (90 deg.) relative to one another. Firstroller 80 is positioned in contact with second roller 86 as seen in FIG.6 and as will be discussed herein first and second rollers 80, 86 willremain in contact with one another in different positions along acircumference of first roller 80 and second roller 86 as positions offirst and second rollers 80, 86 are adjusted.

Roller assembly 62 further includes support 108 positioned relative tofirst and second rollers 80, 86 such that first and second rollers 80,86 are in contact with support 108. In one example, support 108 as seenin FIGS. 3 and 5-9, includes slide block 110. Slide block 110 isconstructed of material which has a low friction surface, which does notadversely affect the composite gap filler member 64 material, whichincludes a number of metallic or composite materials known to those whofabricate composite materials. Gap filler member 64 is pulled throughconverging first and second rollers 80, 86 across slide block 110 withfirst and second rollers 80, 86 imparting first and second curved sides70, 72 to gap filler member 64 and first and second rollers 80, 86 arealso in contact with slide block 110. A second example of support 108 isemployed in roller assembly 62 as seen in FIG. 10. Support 108 shown inFIG. 10 includes conveyor assembly 112 such that belt member 114 ofconveyor assembly 112 is positioned also in contact first and secondrollers 80, 86 and with gap filler member 64 being pulled throughconverging first and second rollers 80, 86 first and second rollers 80,86 impart first and second curved sides 70, 72 to gap filler member 64.Belt member 114 is similarly constructed of material such as slide block110 as discussed above which is compatible for contact with compositematerial of which composite gap filler member 64 is constructed. Withgap filler member 64 positioned on belt member 114 and gap filler member64 being pulled through converging first and second rollers 80, 86, gapfiller is positioned in contact with belt member 114. Belt member 114travels along rollers 116 positioned to permit translational movement ofbelt member 114 relative to rollers 116 allowing belt member 114 to movealong with gap filler member 64.

In referring to FIG. 6, in this example, first support member 82includes first portion 118 and second portion 120 wherein first portion118 of first support member 82 extends along first side 121 of firstroller 80 and second portion 120 of first support member 82 extendsalong second side 122 of first roller 80. Further in this example, firstaxle member 124 includes a bolt member which extends along first axis ofrotation 84 and is supported by first portion 118 of first supportmember 82, extends through first roller 80 and extends to and issupported by second portion 120 of first support member 82. Secondsupport member 88 includes first portion 126 and second portion 128wherein first portion 126 of second support member 88 extends alongfirst side 130 of second roller 86 and second portion 128 of secondsupport member 88 extends along second side 132 of second roller 86.Second axle member 134, which in this example includes a bolt member,extends along second axis of rotation 90 and is supported by the firstportion 126 of second support member 88, extends through second roller86 and extends to and is supported by second portion 128 of secondsupport member 88.

In referring to FIG. 7, roller bearings 136 are positioned between firstframe member 92 and first support member 82 permitting ease in rotationof first support member 82 about third axis of rotation 94. Firstsupport member 82 is connected to first rotatable drive shaft 138 forrotating first support member 82 about third axis of rotation 94. Firstmotor 140, such as a step motor in this example, is connected to firstrotatable drive shaft 138 through drive gears and transmission assembly142 such that rotating first support member 82 rotates first axis ofrotation 84 about third axis of rotation 94. The positions of first axisof rotation 84 with respect to third axis of rotation 94 is seen in FIG.6. This construction of first roller rotational assembly 144 associatedwith first roller 80 is similar to that of the construction of secondroller rotational assembly 146 associated with second roller 86positioned across from first roller rotational assembly 144 with respectto support 108, as seen in FIGS. 3 and 5. Similarly, second rollerrotational assembly 146 is constructed as first roller rotationalassembly 144 wherein roller bearings (not shown) are positioned betweensecond frame member 98 and second support member 88 and second supportmember 88 is connected to second rotatable drive shaft (not shown) forrotating second support member 88 about fourth axis of rotation 100,wherein relative positions of second axis of rotation 90 with respect tofourth axis of rotation 100 can be seen in FIG. 6. Second motor 148, asseen in FIGS. 3 and 5, is connected to second rotatable drive shaft (notshown) such that rotating second support member 88 rotates second axisof rotation 90 about fourth axis of rotation 100. As a result, bothfirst and second rollers 80, 86 rotate about their respective first axisof rotation 84 and second axis of rotation 90 and the first and secondaxis of rotation 84 and 90 can be rotated about respective third axis ofrotation 94 and fourth axis of rotation 100.

As will be further discussed herein, translational movement is alsoimparted to first and second axis of rotation 84, 90 along third andfourth axis of rotation 94, 100 respectively at the same time first andsecond axis of rotation 84, 90 are rotated about third and fourth axisof rotation 94, 100 respectively. This movement of first and secondrollers 80, 86 maintains first and second rollers 80, 86 in contact withone another and in contact with support 108. Translational movement offirst axis of rotation 84 along third axis of rotation 94 isaccomplished with respect to first roller rotational assembly 144 withfirst frame 150 connected to first support member 82 such that withmovement of first frame 150 first support member 82 and first axis ofrotation 84 move along third axis of rotation 94. First frame 150 can beconnected to first support member 82 in various ways. In this example,first frame 150 in FIG. 7 is connected to first frame member 92 andfirst frame member 92 is secured to drive gear and transmission assembly142 of first motor 140. First rotatable drive shaft 138 is connected todrive gear and transmission assembly 142 and is also secured to firstsupport member 82. In this configuration, first frame 150 is connectedto first support member 82. With first frame 150 moving in a directionalong third axis of rotation 94 in this example, first frame member 92,drive gear and transmission assembly 142, first rotatable drive shaft138, first motor 140, first support member 82 and first axis of rotation84 of first roller 80 move along third axis of rotation 94.

First frame 150 imparts translational movement to first support member82 along third axis of rotation 94 with first frame 150 secured to firstball nut 152 and first threaded shaft 154 is connected to first ball nut152, as seen in FIG. 7. First threaded shaft 154 is connected to firstdrive gear and transmission assembly 156 and drive gear and transmissionassembly 156 is connected to first rotation drive motor 158. With firstrotation drive motor 158 activated rotation is imparted to firstthreaded shaft 154 resulting in first ball nut 152 moving up or downfirst threaded shaft 154 depending on the direction of rotation of firstthreaded shaft 154. In turn, movement of first ball nut 152 results infirst frame 150 moving along third axis of rotation 94. First rotationdrive motor 158 in this example is a step motor. Movement imparted tofirst ball nut 152 as a result causes first frame 150 and in turn firstsupport member 82 and first axis of rotation 84 to move in a lineardirection along third axis of rotation 94.

Movement of second axis of rotation 90 along fourth axis of rotation 100is similarly accomplished for second roller 86 associated with secondroller rotational assembly 146 as described above with respect to firstaxis of rotation 84 being moved along third axis of rotation 94associated with first roller rotational assembly 144 and shown in FIG.7. Second frame (not shown), similarly configured as first frame 150, asshown in FIG. 7, is connected to second support member 98 as first frame150 is connected to first support member 82 as described above such thatwith movement of second frame (not shown) second frame member 98 and thesecond axis of rotation 90 move along fourth axis of rotation 100 aswere first support member 82 and first axis of rotation 84 moved alongthird axis of rotation 94.

As similarly shown in FIG. 7 for first frame 150, second frame 151, asseen in FIG. 5, is similarly connected to second frame member 98 andsecond frame 151 is secured to second drive gear and transmissionassembly 153 of second rotation drive motor 155. Second rotatable driveshaft (not shown) is connected to second drive gear and transmissionassembly 153 and is also secured to second support member 88. Withsecond frame member 98 moving in a direction along fourth axis ofrotation 100, second frame member 98, second drive gear and transmissionassembly 153, second rotatable shaft (not shown), second rotation drivemotor 155, second support member 88 and second axis of rotation 90 ofsecond roller 86 move along fourth axis of rotation 100. Second frame151 imparts translational movement to second support member 88 alongfourth axis of rotation 100 with second frame 151 secured to second ballnut 157 and second ball nut is connected to second threaded shaft 159 asis similarly configured as seen in FIG. 7 with respect to correspondingparts discussed above with respect to first roller 80 and first axis ofrotation 84. With second threaded shaft 159 connected to second drivegear and transmission assembly 153 and second drive gear andtransmission assembly 153 connected to second rotation drive motor 155,rotation of second threaded shaft 159 by second rotation drive motor 155results in second ball nut 157 moving up or down second threaded shaft159 depending on the direction of rotation of second threaded shaft 159.In turn, movement of second ball nut 157 results in second frame 151moving along fourth axis of rotation 100. Second rotation drive motor155 in this example is a step motor. Movement imparted to second ballnut 157 causes second frame 151 and in turn second support member 88 andsecond axis of rotation 90 to move along fourth axis of rotation 100.

First and second axis of rotations 84, 90 both are moveable along thirdand fourth axis of rotation 94, 100 respectively in similar fashion.Both first and second axis of rotation 84, 90 in this example operate inthe same fashion as described in the operation of moving first axis ofrotation 84 along third axis of rotation 94 as described above and shownin FIG. 7.

With first roller 80, first axis of rotation 84 and first support member82 and with second roller 86, second axis of rotation 90 and secondsupport member 88 in a first position as seen in FIG. 6, first andsecond rollers 80, 86 are in contact with one another at a firstelevation E with respect to support 108 and first and second rollers 80,86 are in contact with support 108 spaced apart at first distance Dalong support 108. Gap filler member 64 is in contact with first andsecond rollers 80, 86 and with support 108. As gap filler member 64 ispulled through an aperture bounded by first and second rollers 80 and 86and support 108, first and second rollers 80, 86 rotate about first axisof rotation 84 and second axis of rotation 90 respectively with firstand second rollers 80, 86 forming as seen in FIG. 4 adjacent curvedsides 70, 72 which each have radius of curvature 76 and gap fillermember 64 results in being in size S.

With first roller 80, first axis of rotation 84 and the first supportmember 82 and with second roller 86, second axis of rotation 90 andsecond support member 88 moved into a second position as seen in FIG. 9,first support member 82 with first axis of rotation 84 and secondsupport member 88 with second axis of rotation 90 have been each movedalong third and fourth axis of rotation 94, 100 respectively. In thisexample, first axis and second axis of rotation 84, 90 have been movedin directions 160 and 162 along third axis and fourth axis of rotation94, 100 respectively as seen in FIG. 8. Also as this is occurring, firstsupport member 82 with first axis of rotation 84 and second supportmember 88 with second axis of rotation 90 have been each rotated inopposite rotational directions 164, 166 respectively as seen in FIG. 8about third axis and fourth axis of rotation 94, 100 respectively.

With translation and rotation of first axis of rotation 84 and secondaxis of rotation 90 together, first and second rollers 80, 86 maintainin contact with one another in moving from the first position as seen inFIG. 6 at first elevation E with respect to support 108 to the secondposition as seen in FIG. 9 at second elevation E′ as seen in FIG. 9.First and second rollers 80, 86 also remain in contact with support 108as seen in FIG. 6 in moving first and second rollers 80, 86 to thesecond position as seen in FIG. 9. Gap filler member 64 is in contactwith first and second rollers 80, 86 and with support 108.

As gap filler member 64 is pulled through first and second rollers 80,86 and first and second rollers 80, 86 changes from first position asseen in FIG. 6 to second position as seen in FIG. 9, first and secondrollers 80, 86 continue to rotate about first and second axis ofrotation 84, 90 respectively as gap filler member 64 passes throughfirst and second rollers 80, 86 forming adjacent curved sides 70, 72from first radius of curvature 76 to second radius of curvature 78. Inaddition, gap filler member 64 increases in size from size S to size S′as seen in FIG. 4 as gap filler 64 extends in a direction along lengthL′ of gap filler 64 from first end 74 toward second end 75. Thecontinuous and simultaneous movement of rotation and translation offirst and second axis of rotation 84, 90, and the continued rotation ofthe first and second rollers 80, 86 as gap filler member 64 is pulledthrough first and second rollers 80, 86, allows first and second rollers80, 86 to impart smooth transition with respect to size and radius ofcurvature of gap filler member 64, as first and second rollers 80, 86move from first position of FIG. 6 to second position as seen in FIG. 9without imparting abrupt surface changes to gap filler member 64 indoing so.

This rotational and translational movement of first and second axis ofrotation 84, 90 can be reversed by reversing the direction of rotationaldirections 164, 166 of rotation of first and second axis of 84, 90 andat the same time reversing the directions 160 and 162 of translationalmovement of first and second axis of rotation 84, 90 along third andfourth axis of rotation 94, 100 respectively. Reversing of rotationaldirections 164, 166 and directions 160, 162 of translational movement offirst and second axis of rotation 84, 90 results in reducing size S′ ofgap filler 64 in FIG. 9 to size S as seen in FIG. 6 and also reducingthe radius of curvature from radius of curvature 78 of adjacent curvedsides 70, 72 as seen in FIG. 9 to radius of curvature 76 of adjacentcurved sides 70, 72 as seen in FIG. 6. This is also seen in gap fillermember 64 in FIG. 4 as gap filler member 64 extends along length L′ froma central portion of gap filler member 64 toward second end 75.

As mentioned above, the continuous and simultaneous movement of rotationand translation of first and second axis of rotation 84, 90, and thecontinued rotation of the first and second rollers 80, 86 about firstand second axis of rotation 84, 90 respectively as gap filler member 64is pulled through first and second rollers 80, 86 allows first andsecond rollers 80, 86 to impart smooth transition to the surfaces of gapfiller member 64 with imparting change to size and radius of curvatureof gap filler member 64.

Roller assembly 62 having first and second rollers 80, 86 move fromfirst position of FIG. 6 to second position of FIG. 9 and to move fromsecond position of FIG. 9 to first position of FIG. 6, imparts a smoothtransition to surfaces of gap filler member 64 with changing of size andradius of curvature of adjacent sides of gap filler member 64 withoutimparting abrupt surface changes to gap filler member 64 in doing so.

In referring to the flow chart of FIG. 11, method 168 is provided offorming adjacent curved sides 70, 72 in a composite gap filler member 64which includes step 170 of positioning first roller 80 against compositematerial for gap filler member 64 with first roller 80 supported byfirst support member 82. First roller 80 rotates relative to firstsupport member 82 about first axis of rotation 84. First support member82 is rotatable about third axis of rotation 94 which extends indirection 96 transverse to first axis of rotation 84. Method 168 furtherincludes step 172 of positioning second roller 86 against compositematerial for gap filler member 64 with second roller 86 supported bysecond support member 88. Second roller 86 rotates relative to secondsupport member 88 about second axis of rotation 90. Second supportmember 88 is rotatable about fourth axis of rotation 100 which extendsin direction 102 transverse to second axis of rotation 90. Method 168further includes step 174 of pulling the composite material of gapfiller member 64 past first and second rollers 80, 86 wherein firstroller 80 rotates about first axis of rotation 84 and second roller 86rotates about second axis of rotation 90. Pulling of the compositematerial for gap filler member 64 can be done by a number of waysconventionally known in the art which applies tension to the compositematerial being pulled past first and second rollers 80, 86. In addition,method 168 includes step 176 of rotating first axis of rotation 84 aboutthird axis of rotation 94 and rotating second axis of rotation 90 aboutfourth axis of rotation 100 as discussed earlier.

Method 168 further includes a step of positioning first roller 80 andsecond roller 86 into contact with one another and a step of positioningthe first and second rollers 80, 86 into contact with support 108. Inaddition, method 168 includes a step of moving first axis of rotation 84along third axis of rotation 94 and moving second axis of rotation alongfourth axis of rotation 100 as also previously discussed. The moving offirst axis of rotation 84 and second axis of rotation 94 along third andfourth axis of rotation 94, 100 respectively allows first and secondrollers 80, 86 to not interfere with rotational movement of first andsecond rollers 80, 86 about third and fourth axis of rotation 94, 100respectively with first and second axis of rotation 84, 90 being rotatedabout third and fourth axis of rotation 94, 100 respectively. With thisrotational movement of first and second axis of rotation 84, 90 aboutthird and fourth axis of rotation 94, 100 respectively along withtranslational movement of first and second axis of rotation 84, 90 alongthird and fourth axis of rotation 94, 100 respectively, this maintainsfirst and second rollers 80, 86 in contact with one another andmaintains first and second rollers 80, 86 in contact with support 108.As a result, smooth transitions occur with respect to changes of radiusof curvature for adjacent curved sides 70, 72 as well as with the changein size of gap filler member 64 with first and second rollers 80, 86 incontact with composite material for gap filler member 64.

In referring to FIG. 12, a second embodiment of roller assembly 62′ isshown. Second embodiment of roller assembly 62′ includes the features ofroller assembly 62 as described earlier. For example, first and secondrollers 80, 86 impart external surfaces 66 and 68 of gap filler member64, as seen in FIG. 4, such that external surfaces 66 and 68 smoothlytransition in changing radius of curvature of adjacent curved sides 70,72 in forming symmetric adjacent curved sides 70, 72 of gap fillermember 64 along length L′ of gap filler member 64, as desired. Inaddition, roller assembly 62′ also provides the features of rollerassembly 62 to provide smooth transition in changing size ofsymmetrically formed gap filler member 64 along length L′ as desired,such as also seen for example in FIG. 4.

In addition, second embodiment of roller assembly 62′, as will bedescribed, can provide smooth transition of adjacent curved sides 70, 72to each have a different radius of curvature such that composite gapfiller member 64 can be asymmetric in configuration along L′ of gapfiller member 64 as desired, as seen in FIG. 16. In referring to FIG.16, gap filler member 64 is configured with roller assembly 62′ suchthat roller assembly 62′ at location 63, along length L′ of gap fillermember 64, imparts first gap filler member radius 65 on adjacent curvedside 70 which has the same radius dimension as second gap filler memberradius 67 on adjacent curved side 72 and as gap filler member 64progresses along length L′ of gap filler member 64 to location 69, thirdgap filler member radius 71 on adjacent curved side 70 has a differentradius dimension as fourth gap filler member radius 73 on adjacentcurved side 72. Second embodiment of roller assembly 62′, as will bediscussed, can smoothly transition to form gap filler member 64 to havean asymmetric configuration of adjacent curved sides 70, 72 along lengthL′.

Second embodiment of roller assembly 62′, as seen in FIGS. 12 and 14,for forming adjacent curved sides 70, 72, as seen in FIG. 16, incomposite gap filler member 64, includes first roller 80 supported byfirst support member 82 wherein first roller 80 rotates relative tofirst support member 82, in this example, about first axis of rotation84, as seen in FIG. 14. Second roller 86 is supported by second supportmember 88 wherein second roller 86 rotates relative to second supportmember 88, in this example, about second axis of rotation 90. Firstsupport member 82 is rotatable about third axis of rotation 94 and thirdaxis of rotation 94, in this example, extends in a direction 96transverse to first axis of rotation 84. Second support member 88 isrotatable about fourth axis of rotation 100 and fourth axis of rotation100, in this example, extends in direction 102 transverse to second axisof rotation 90.

Second embodiment of roller assembly 62′ further includes support 108which includes surface 109. Surface 109 is associated with first andsecond rollers 80, 86 with first roller 80 and second roller 86 incontact at location P1, as seen for example, in FIG. 13, with oneanother and first roller 80 in contact at location P2 with surface 109and second roller 86 in contact at location P3 with surface 109.

With rotation of first roller 80 about third axis of rotation 94 fromposition of first roller 80, as seen in FIG. 13, to a position of firstroller 80 as shown in FIGS. 14 and 15, with at least one of the firstroller 80 or second roller 86 moved relative to the other such thatfirst roller 80 maintains contact with second roller 86 and first rollerand second roller maintain contact with surface 109, first roller 80,second roller 86 and surface 109 form aperture 113 as seen in FIG. 15.

In this example, first roller 80, which was positioned in contact withsurface 109 at location P2 in FIG. 13, has been moved along surface 109closer to second roller 86 to location P2′, as seen in FIGS. 14 and 15,such that with first roller 80 rotating about third axis of rotation 94first roller 80 maintains contact with second roller 86. This contactbetween first roller 80 and second roller 86 is seen with first roller80 in FIG. 13 in contact with second roller 86 at location P1 relativeto surface 109 prior to rotation of first roller 80 and remains incontact with second roller 86 as first roller rotates about third axisof rotation 94 as seen in FIG. 15 with first roller 80 being in contactwith second roller 86 at location P1′ relative to surface 109 of support108. In this example, as first roller 80 is rotated about third axis ofrotation 94 and first roller 80 is at the same time moved along surface109 toward second roller 86, first and second rollers 80, 86 stay incontact with one another changing in position of contact from locationP1 to location P1′ and first roller 80 remains in contact with surface109 changing in position from P2 to P2′. In this example, second roller86 which is not moved along surface 109 and is not rotated relative tofourth axis of rotation 100 remains in contact with surface 109 atposition P3.

Aperture 113, as seen in FIG. 15, includes first roller 80 which definesfirst curved side 115 having first radius 117 and second roller 86defines second curved side 119, adjacent to first curved side 115,having second radius 141 such that first radius 117 and second radius141 are unequal. As a result of this configuration of aperture 113,first curved side 115 having first radius 117 corresponds to impartingto gap filler 64 member curved side 70 having third gap filler memberradius 71 as seen in FIG. 16 and second curved side 119 having secondradius 141 corresponds to imparting to gap filler member 64 curved side72 having fourth gap filler member radius 73, as seen in FIG. 16.

With first roller 80 and second roller 86 in contact with one anotherand in contact with surface 109 as seen in FIG. 13, a second aperture111 is defined. In this example, the shape of second aperture 111includes first roller 80 defining first curved side 123 having a firstradius 125 and second roller 86 defining second curved side 127, havingsecond radius 129, adjacent to first curved side 123, wherein firstradius 125 equals second radius 129. As a result of this example ofconfiguration of second aperture 111, first curved side 123 having firstradius 125 corresponds to imparting to gap filler member 64 curved side70 having first gap filler member radius 65 and second curved side 127having second radius 129 corresponds to imparting to gap filler member64 second curved side 72 having second gap filler member radius 67, asseen in FIG. 16. As a result, gap filler member 64, which is pulledthrough second aperture 111, results in curved side 70 and curved side72 of gap filler member 64 being symmetric.

A smooth transformation in changing between of configurations ofaperture 113 and second aperture 111 can be easily accomplished withroller assembly 62′ which imparts a smooth transition in forming theshape of gap filler 64 as gap filler member 64 passes through aconfigured aperture. For example, in changing between a symmetricconfigured aperture such as second aperture 111 to an asymmetricconfigured aperture 113, this can be accomplished with a minimum ofmovement of one roller being rotated about either the third or fourthaxis of rotation 94, 100 and at least one of one roller or the otherroller being moved relative to the other such that the rollers maintaincontact with one another as the one roller rotates about either thethird or fourth axis of rotation 94, 100 and the rollers maintaincontact with surface 109 of support 108. This smooth transition resultsin providing corresponding smooth transition to adjacent curved walls70, 72 along length L′ of gap filler 64. The smooth transformation inchanging shape of aperture through which composite gap filler member 64passes resulting in smooth transition of adjacent curved walls 70, 72along length L′ of gap filler member 64 can also, for example, beaccomplished with both rollers being rotated about third and fourth axesof rotation 94, 100 and at least one of one roller or the other rollerbeing moved relative to the other roller such that the rollers maintaincontact with one another as each roller rotates about one of the thirdand fourth axis of rotation 94, 100 and as each roller maintains contactwith surface 109 of support 108. As a result, gap filler member 64maintains smooth transition with respect to changing and formingadjacent curved sides 70, 72, such as in this example of transitioningfrom symmetric gap filler member 64 configuration to having differentradius of curvature and forming an asymmetric gap filler member 64configuration. This transitioning from a symmetric configuration for gapfiller member 64 to an asymmetric configuration for gap filler member 64can be applied with transitioning from an asymmetric configuration forgap filler member 64 to a symmetric configuration for gap filler member64 with similar movements of the rollers.

In referring to FIG. 13, second aperture 111 includes plane of symmetry131 which is co-planar to a plane of symmetry of gap filler member 64that would be formed by second aperture 111. As mentioned earlier, atleast one of first roller 80 or second roller 86 is moved relative tothe other. In referring to FIG. 15, at least one of first roller 80 orsecond roller 86 is moved in direction 133 transverse with respect toplane of symmetry 131 and in this example first roller 80 is movedtoward second roller 86 in direction 133 transverse with respect toplane of symmetry 131. This movement, as mentioned earlier, maintainsfirst roller 80 in contact with surface 109 and maintains first roller80 and second roller 86 in contact with one another as first roller 80is rotated about, in this example, third axis of rotation 94.

In further referring to FIG. 13, third axis of rotation 94 extends indirection 96 and fourth axis of rotation 100 extends in direction 102.With respect to this example of second aperture 111, third and fourthaxis of rotation 94, 100 intersect at first location 135 along plane ofsymmetry 131 of second aperture 111. With rotation of first roller 80,as seen with respect to FIGS. 13 and 15, and movement of first roller80, in this example, in direction 133 transverse with respect to planeof symmetry 13, as seen in FIGS. 13 and 15, aperture 113, as seen inFIG. 15, is formed and third and fourth axes of rotation 94, 100intersect at second location 137 spaced apart from plane of symmetry 131which had been defined by second aperture 111.

As mentioned earlier, with rotation, in this example, of first roller 80about third axis of rotation 94 and with at least one of first roller 80or second roller 86 being moved relative to the other such that thefirst roller 80 maintains contact with second roller 86 and first roller80 and second roller 86 maintain contact with surface 109, first roller80, second roller 86 and surface 109 form aperture 113, as seen in FIG.15. In this example, the movement of the rollers relative to the otheris movement of first roller 80 toward second roller 86 in direction 133transverse to plane of symmetry 131, as earlier mentioned. Impartingmovement of first roller 80, in this example, is accomplished, as seenin FIG. 12, with drive mechanism 178 which imparts linear movement toshaft 179. Shaft 179 is secured to first support structure 180, whichprovides support to first support member 82 and first roller 80, withbracket 182. Drive mechanism 178 includes a power source of one of apneumatic cylinder, hydraulic cylinder or a servo motor associated withthe shaft 179 such that shaft 179 can extend or contract in a lineardirection. First support structure 180 includes rail guide 184 whichengages rail 186. Rail 186 extends in direction 133 transverse to planeof symmetry 131, as seen in FIGS. 12 and 15, which guides travel offirst support member 82 in direction 133. Platform 188, in this exampleas seen in FIG. 12, provides support to rail 186 and support 108.

As described earlier with respect to FIG. 6, with respect to an exampleof roller assembly 62, the same features apply in the example withrespect to second embodiment of roller assembly 62′. First supportmember 82 includes first portion 118 and second portion 120 whereinfirst portion 118 of first support member 82 extends along first side121 of first roller 80 and second portion 120 of first support member 82extends along second side 122 of first roller 80. First axle member 124includes a bolt member which extends along first axis of rotation 84 offirst roller 80 and is supported by first portion 118 of first supportmember 82, extends through first roller 80 and extends to and issupported by second portion 120 of first support member 82. Secondsupport member 88 includes first portion 126 and second portion 128wherein first portion 126 of second support member 88 extends alongfirst side 130 of second roller 86 and second portion 128 of secondsupport member 88 extends along second side 132 of second roller 86.Second axle member 134, which in this example includes a bolt member,extends along second axis of rotation 90 of second roller 86 and issupported by the first portion 126 of second support member 88, extendsthrough second roller 86 and extends to and is supported by secondportion 128 of second support member 88.

Similarly second embodiment of roller assembly 62′ includes the featuresas shown and described earlier with respect to FIGS. 7 and 8 for rollerassembly 62. Second embodiment of roller assembly 62′ includes rollerbearings 136 being positioned between first frame member 92 and firstsupport member 82 permitting ease in rotation of first support member 82about third axis of rotation 94 and relative to first frame 150. Firstsupport member 82 is connected to first rotatable drive shaft 138 forrotating first support member 82 about third axis of rotation 94. Firstmotor 140, such as a step motor in this example, is connected to firstrotatable drive shaft 138 through drive gears and transmission assembly142 such that rotating first support member 82 rotates first axis ofrotation 84 about third axis of rotation 94. The position of first axisof rotation 84 with respect to third axis of rotation 94 is seen inFIGS. 6 and 14. This construction of first roller rotational assembly144 associated with first roller 80 is similar to that of theconstruction of second roller rotational assembly 146 associated withsecond roller 86 positioned across from first roller rotational assembly144 with respect to support 108, as seen in FIGS. 3, 5 and 12 for eachof roller assembly 62 and second embodiment of roller assembly 62′.Similarly, second roller rotational assembly 146 is constructed as firstroller rotational assembly 144 wherein roller bearings (not shown) arepositioned between second frame member 98 and second support member 88and second support member 88 is connected to second rotatable driveshaft (not shown) for rotating second support member 88 about fourthaxis of rotation 100, wherein relative positions of second axis ofrotation 90 with respect to fourth axis of rotation 100 can be seen inFIGS. 6 and 14. Second motor 148, as seen in FIGS. 3 and 5, is connectedto second rotatable drive shaft (not shown) such that rotating secondsupport member 88 rotates second axis of rotation 90 about fourth axisof rotation 100. As a result, both first and second rollers 80, 86rotate about their respective first axis of rotation 84 and second axisof rotation 90 and the first and second axis of rotation 84 and 90 canbe rotated about respective third axis of rotation 94 and fourth axis ofrotation 100.

Second embodiment of roller assembly 62′ also has first support member82 movable along third axis of rotation 94 and second support member 88movable along fourth axis of rotation 100 as was also provided anddiscussed earlier with respect to roller assembly 62. Translationalmovement is imparted to first and second axis of rotation 84, 90 alongthird and fourth axis of rotation 94, 100 respectively at the same timefirst and second axis of rotation 84, 90 are rotated about third andfourth axis of rotation 94, 100 respectively. This movement of first andsecond rollers 80, 86 maintains first and second rollers 80, 86 incontact with one another and in contact with support 108. Translationalmovement of first axis of rotation 84 along third axis of rotation 94 isaccomplished with respect to first roller rotational assembly 144 withfirst frame 150 connected to first support member 82 such that withmovement of first frame 150 first support member 82 and first axis ofrotation 84 move along third axis of rotation 94. First frame 150, asdescribed earlier, can be connected to first support member 82 invarious ways. In this example, first frame 150 in FIG. 7 is connected tofirst frame member 92 and first frame member 92 is secured to drive gearand transmission assembly 142 of first motor 140. First rotatable driveshaft 138 is connected to drive gear and transmission assembly 142 andis also secured to first support member 82. In this configuration, firstframe 150 is connected to first support member 82. With first frame 150moving in a direction along third axis of rotation 94 in this example,first frame member 92, drive gear and transmission assembly 142, firstrotatable drive shaft 138, first motor 140, first support member 82 andfirst axis of rotation 84 of first roller 80 move along third axis ofrotation 94.

First frame 150, for second embodiment of roller assembly 62′, asdescribed earlier with respect to roller assembly 62, impartstranslational movement to first support member 82 along third axis ofrotation 94 with first frame 150 secured to first ball nut 152 and firstthreaded shaft 154 is connected to first ball nut 152, as seen in FIG. 7with respect to roller assembly 62. First threaded shaft 154 isconnected to first drive gear and transmission assembly 156 and drivegear and transmission assembly 156 is connected to first rotation drivemotor 158. With first rotation drive motor 158 activated rotation isimparted to first threaded shaft 154 resulting in first ball nut 152moving up or down first threaded shaft 154 depending on the direction ofrotation of first threaded shaft 154. In turn, movement of first ballnut 152 results in first frame 150 moving along third axis of rotation94. First rotation drive motor 158 in this example is a step motor.Movement imparted to first ball nut 152 as a result causes first frame150 and in turn first support member 82 and first axis of rotation 84 tomove in a linear direction along third axis of rotation 94.

As was previously discussed with respect to roller assembly 62, secondembodiment of roller assembly 62′ also includes movement of second axisof rotation 90 along fourth axis of rotation 100 which is similarlyaccomplished for second roller 86 associated with second rollerrotational assembly 146 as described above with respect to first axis ofrotation 84 being moved along third axis of rotation 94 associated withfirst roller rotational assembly 144 and shown in FIG. 7. Second frame(not shown), similarly configured as first frame 150, as shown in FIG.7, is connected to second support member 98 as first frame 150 isconnected to first support member 82 as described above such that withmovement of second frame (not shown) second frame member 98 and thesecond axis of rotation 90 move along fourth axis of rotation 100 aswere first support member 82 and first axis of rotation 84 moved alongthird axis of rotation 94.

In referring to FIG. 17, method 190 of forming adjacent curved sides 70,72 in composite gap filler member 64 is shown and includes step 192 ofpositioning first roller 80, which is supported by first support member82 in contact with surface 109 of support 108. First roller 80 rotatesrelative to first support member 82 about first axis of rotation 84 andfirst support member 82 is rotatable about third axis of rotation 94which extends in a direction transverse to first axis of rotation 84.Step 194 includes positioning second roller 86, which is supported bysecond support member 88, in contact with surface 109 of support 108 andin contact with first roller 80. Second roller 86 rotates relative tosecond support member 88 about second axis of rotation 90 and secondsupport member 88 is rotatable about fourth axis of rotation 100 whichextends in direction 102 transverse to second axis of rotation 90. Firstroller 80, second roller 86 and surface 109 of support 108 define secondaperture 111 as seen in FIG. 13. Positioning of first roller 80, in thisexample, includes first roller 80 defining first curved side 123, asseen in FIG. 13, having first radius 125 and positioning second roller86 includes second roller 86 defining second curved side 127 havingsecond radius 129 in defining second aperture 111 such that first radius125 equals second radius 129, which in this forms, in this example, asymmetric first and second curved sides 123, 127.

Method 190 further includes step 196 of pulling composite material, asused in constructing gap filler member 64, in contact with and pastfirst and second rollers 80, 86 wherein first roller 80 rotates aboutfirst axis of rotation 84 and second roller 86 rotates about second axisof rotation 90 imparting adjacent curved sides 70, 72 in forming gapfiller member 64. Method 190 further includes step 198 of rotating firstsupport member and first roller 80 about third axis of rotation 94 andmoving at least one of first roller 80 or second roller 86 relative tothe other maintaining first and second rollers 80, 86 in contact withone another and in contact with surface 109 of support 108. First roller80, second roller 86 and surface 109 of support 108 define aperture 113,as seen in FIG. 15. First roller 80 defines first curved side 115 havingfirst radius 117 and second roller 86 defines second curved side 119,adjacent to the first curved side 115, having a second radius 141 suchthat first radius 117 and second radius 141 are unequal.

While various embodiments have been described above, this disclosure isnot intended to be limited thereto. Variations can be made to thedisclosed embodiments that are still within the scope of the appendedclaims.

What is claimed:
 1. A roller assembly for forming adjacent curvedsurfaces in a composite gap filler member, comprising: a first roller issupported by a first support member wherein the first roller rotatesrelative to the first support member about a first axis of rotation; asecond roller is supported by a second support member wherein the secondroller rotates relative to the second support member about a second axisof rotation, wherein: the first support member is rotatable about athird axis of rotation, which provides for rotation of the first axis ofrotation about the third axis of rotation; and the second support memberis rotatable about a fourth axis of rotation, which provides forrotation of the second axis of rotation about the fourth axis ofrotation; and a support comprising a surface, wherein: with the firstroller and the second roller in contact with one another and in contactwith the surface and with rotation of the first roller about the thirdaxis of rotation and with at least one of the first roller or secondroller is moved relative to other, such that the first roller maintainscontact with the second roller and the first roller and the secondroller maintain contact with the surface, the first roller, secondroller and the surface form an aperture; and the aperture includes thefirst roller defining a first curved side of the aperture having a firstradius and the second roller defines a second curved side of theaperture, adjacent to the first curved side, having a second radius suchthat the first radius and the second radius are unequal.
 2. The rollerassembly of claim 1, wherein with the first roller and the second rollerin contact with one another and in contact with the surface a secondaperture is formed with the first roller defining a first curved side ofthe second aperture having a first radius and the second roller definesa second curved side of the second aperture adjacent to the first curvedside having a second radius with the first radius equal to the secondradius.
 3. The roller assembly of claim 2, wherein the second apertureincludes a plane of symmetry wherein with the at least one of the firstroller or the second roller is moved relative to other, the at least oneof the first roller or the second roller is moved in a directiontransverse with respect to the plane of symmetry.
 4. The roller assemblyof claim 3, wherein: the third axis of rotation extends in a firstdirection and the fourth axis of rotation extends in a second direction;and with respect to the second aperture, the third and fourth axis ofrotation intersect at a first location along the plane of symmetry ofthe second aperture.
 5. The roller assembly of claim 4, wherein withrespect to the aperture, the third and fourth axes of rotation intersectat a second location spaced apart from the plane of symmetry.
 6. Theroller assembly of claim 3, further includes: a drive mechanism whichimparts linear movement to a shaft; and the shaft is secured to a firstsupport structure, which provides support to the first support memberand the first roller.
 7. The roller assembly of claim 6, wherein thedrive mechanism comprises one of a pneumatic cylinder, hydrauliccylinder or a servo motor associated with the shaft.
 8. The rollerassembly of claim 6, further includes a bracket which secures the shaftto the first support structure.
 9. The roller assembly of claim 6,wherein the first support structure includes a rail guide which engagesa rail.
 10. The roller assembly of claim 9, wherein the rail extends inthe direction transverse to the plane of symmetry.
 11. The rollerassembly of claim 9, further includes a platform supporting the rail andthe support.
 12. The roller assembly of claim 1, wherein: the firstsupport member comprises a first portion and second portion wherein thefirst portion of the first support member extends along a first side ofthe first roller and the second portion of the first support memberextends along a second side of the first roller; and a first axle memberextends along a first axis of rotation of the first roller and issupported by the first portion of the first support member, extendsthrough the first roller and extends to and is supported by the secondportion of the first support member.
 13. The roller assembly of claim 1,wherein: the second support member comprises a first portion and secondportion wherein the first portion of the second support member extendsalong a first side of the second roller and the second portion of thesecond support member extends along a second side of the second roller;and a second axle member extends along a second axis of rotation of thesecond roller and is supported by the first portion of the secondsupport member, extends through the second roller and extends to and issupported by the second portion of the second support member.
 14. Theroller assembly of claim 1, further includes roller bearings positionedbetween a first frame member and the first support member wherein: thefirst support member rotates relative to the first frame member; and thefirst support member is connected to a first rotatable drive shaft forrotating the first support member about the third axis of rotation. 15.The roller assembly of claim 14, further includes a first motorconnected to the first rotatable drive shaft such that rotating thefirst support member rotates a first axis of rotation of the firstroller about the third axis of rotation.
 16. The roller assembly ofclaim 1, further includes roller bearings positioned between a secondframe member and the second support member, wherein: the second supportmember rotates relative to the second frame member; and the secondsupport member is connected to a second rotatable drive shaft forrotating the second support member about the fourth axis of rotation.17. The roller assembly of claim 16, further includes a second motorconnected to the second rotatable drive shaft such that rotating thesecond support member rotates a second axis of rotation of the secondroller about the fourth axis of rotation.
 18. The roller assembly ofclaim 1, further includes the first support member is movable along thethird axis of rotation and the second support member is movable alongthe fourth axis of rotation.
 19. A method of forming adjacent curvedsurfaces in a composite gap filler member, comprising the steps of:positioning a first roller, which is supported by a first supportmember, in contact with a surface of a support, wherein: the firstroller rotates relative to the first support member about a first axisof rotation; and the first support member is rotatable about a thirdaxis of rotation, which provides for rotation of the first axis ofrotation about the third axis of rotation; positioning a second roller,which is supported by a second support member, in contact with thesurface of the support and in contact with the first roller, wherein:the second roller rotates relative to the second support member about asecond axis of rotation; and the second support member is rotatableabout a fourth axis of rotation, which provides for rotation of thesecond axis of rotation about the fourth axis of rotation; and pulling acomposite material in contact with and past the first and second rollerswherein the first roller rotates and the second roller rotates; androtating the first support member and the first roller about the thirdaxis of rotation and moving at least one of the first roller or secondroller relative to other maintaining the first and second rollers incontact with one another and in contact with the surface, wherein: thefirst roller, the second roller and the surface of the support define anaperture; and the first roller defines a first curved side of theaperture having a first radius and the second roller defines a secondcurved side, adjacent to the first curved side of the aperture, having asecond radius such that the first radius and the second radius areunequal.
 20. The method of claim 19, wherein the positioning the firstroller includes the first roller defining a first curved side having afirst radius and positioning the second roller includes the secondroller defining a second curved side having a second radius in defininga second aperture such that the first radius equals the second radius.